Exhaust Gas Recirculation (EGR) Cooler: Installation

WARNING: This page is about a different variant/trim than selected.

NOTE: Make sure that the mating faces are clean and free of foreign material.

1.

Install the new EGR cooler gasket.

GFD145094

Courtesy of FORD MOTOR COMPANY

2.
- Position the EGR cooler and install the EGR cooler mounting bolt finger tight at this stage.
- Install the EGR cooler tube mounting bolt finger tight at this stage.

GFD145092

Courtesy of FORD MOTOR COMPANY

3.

NOTE: Make sure that a new EGR cooler vee-clamp and a new EGR cooler vee-clamp nut is installed.

Install the new EGR cooler vee-clamp and the EGR cooler vee-clamp nut positioned as shown in illustration. Tighten the EGR cooler vee-clamp nut.

Torque: 80 lb.in (9.0 Nm)

GFD145095

Courtesy of FORD MOTOR COMPANY

4.

Torque:
Tighten the EGR (exhaust gas recirculation) cooler mounting bolt. : 17 lb.ft (23 Nm)

Tighten the EGR (exhaust gas recirculation) cooler tube mounting bolt. : 17 lb.ft (23 Nm)

GFD145096

Courtesy of FORD MOTOR COMPANY

5.

Connect and tighten the EGR cooler hose.
Torque: 33 lb.in (3.7 Nm)

GFD145091

Courtesy of FORD MOTOR COMPANY

6.
- 1.
  
  NOTE: Install the rear exhaust manifold heat shield bolts and the turbocharger heat shield bolt finger tight at this stage.
  
  Tighten the rear exhaust manifold heat shield bolt.
  
  Torque: 89 lb.in (10 Nm)
- 2.
  
  Tighten the rear exhaust manifold heat shield bolt.
  Torque: 89 lb.in (10 Nm)
- 3.
  
  Tighten the rear exhaust manifold heat shield bolt.
  Torque: 89 lb.in (10 Nm)
- 4.
  
  Tighten the turbocharger heat shield bolt.
  Torque: 18 lb.ft (25 Nm)

Fig 1: Rear Exhaust Manifold Heat Shield Tightening Sequence

GFD145097

Courtesy of FORD MOTOR COMPANY

7.

Install a new replacement clamp and connect the EGR cooler bypass valve solenoid vacuum hose and attach the EGR cooler bypass valve solenoid vacuum harness retainers.

GFD145098

Courtesy of FORD MOTOR COMPANY

8.

Install the EGR valve. Refer to: Exhaust Gas Recirculation (EGR) Valve .